Fiber Optic End-Face Transparent Protector System and Method

ABSTRACT

A protective assembly method using a transparent layer within the fiber interconnect system aids in optical coupling by preventing an air gap from forming between the fiber cores within a connector. A fiber protection device made of a thin transparent film, which includes an adhesive layer, is applied over the fiber end-faces at the connector interface, the film having characteristics which allows it to conform to the fiber end and minimize coupling loss between fibers. According to one aspect, the film is part of a cartridge that provides structural support for the film to facilitate application of the fiber protection device. The film may be divided by perforate patterns that define one or more fiber protection devices formed by the film. The assembly method can include usage of an applicator base plate upon which the cartridge is mounted. According to another aspect, the film may be part of a single-use disposable pod for application of a single fiber protection device.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation-in-part of U.S. patentapplication Ser. No. 15/699,484 filed Sep. 8, 2017, which, in turn is acontinuation of U.S. patent application Ser. No. 14/752,986, filed Jun.28, 2015 (now U.S. Pat. No. 9,784,924 issued Oct. 10, 2017), whichclaims the benefit of U.S. Provisional Patent Application No.62/019,405, filed Jun. 30, 2014, the contents of all of which are herebyincorporated by reference in their entirety.

The present application is related to U.S. application Ser. No. ______entitled “Single-Use Disposable Pod for Application of an Optical FiberProtection Device” (Attorney Docket No. UC-011-PAP) filed on even dateherewith and incorporated herein by reference in its entirety.

TECHNICAL FIELD

The present disclosure relates to fiber optic connector interfaces andmethods for applying same. Embodiments according to the presentdisclosure aid in protecting the tip of a fiber, especially the regionthat guides light, while allowing light coupling between fibers. Theembodiments according to the present disclosure can be used to protectfiber optic connector end-faces during the manufacturing process ofcables and also during the general use of fiber optic cables.

BACKGROUND

Fiber optic cables are often connected together by aligning and pressingthe ends of two fibers together. The end of the fibers (the ‘end-faces’)are typically polished smooth and flat, or at an angle. The opticalcoupling occurs between the cores of the fibers, which is the centralportion of the fiber that guides the optical energy. The types of fibercan be single-mode-fiber (SMF), with a core that is usually 9 microns indiameter, or multi-mode-fiber (MMF), with a core that is much larger,but typically between 50 to 100 microns in diameter. Efficient opticalcoupling occurs when the cores of the two fibers are aligned and inphysical contact. Ideally, nearly 100% of the light is coupled betweenthe two fibers, but in practice, a loss of up to 0.3 dB may beacceptable.

Imperfections in the fiber end-face polished surface or contaminationtrapped between the cores of the fibers can reduce the efficiency of theoptical coupling. These imperfections can also create an increasedamount of back-reflected light from the connector interface.Imperfections can arise during the handling and use of the fiber.Imperfections can be in the form of scratches or other mechanical damageto the end-face of the fiber. Contamination can result from liquidsources or oils on the fiber end-face. Contamination can also resultfrom particles trapped within the fiber-to-fiber interface. Particlescan originate from the connector itself, for example, from the regionswhere the mechanical alignment mechanisms engage (such as guide holes),or from external sources, such as dust in the environment outside theconnector. A trapped particle can further damage the end-face polish ifthe particle hardness is similar or greater that the glass in the fibercore. A particle can create scratches on the fiber end-face.

The optical coupling efficiency between the two fiber cores is reducedif the fiber cores are not in physical contact and an air gap is createdbetween the cores. An air gap will create a Fresnel reflection ofapproximately 4% at each of the two core-to-air interfaces, a doubleFresnel reflection. If this light is coherent, the interference of thereflections can create additional coupling loss.

Multi-fiber connectors are designed to bring two arrays of fiberend-faces into alignment and create physical contact between the fibercores. The manufacturing process typically polishes the fiber connectorend-face, polishing multiple fibers simultaneously. The polishingprocess typically leaves the tips of the fibers slightly protruding fromthe connector face by 1 to 3 microns. This allows two connectors to mateand have the fiber end-faces make physical contact.

The protrusions of the fiber tips on the connector are not typicallyperfectly uniform. The polishing process may leave a taper or acurvature across the array. Therefore, there is a provision in theconnector to allow the fibers to recess under pressure. A spring can beprovided within the connector to create the pressure. As two fiberconnectors mate, the fibers that have a greater protrusion will comeinto contact first. Under pressure, these two fibers will recede intotheir connector until fibers with less protrusion make physical contact.

A failure in the recess mechanism may make a fiber fail to rebound afterit has been recessed. This failure is called ‘pistoning’. The fiber tiphas been pressed down into the connector, but does not restore to aprotruding state after un-mating of the connector. Pistoning can causefailure of a subsequent mating, as the fiber is not protruding enough tocreate physical contact.

Damage may occur to the fiber end-face during the process ofmanufacturing the fiber optic cable. There may be steps of handling thecable for testing, inspection or installation of the cable into ahigher-level assembly. The manufacturer may ship the cable to a customerthat further handles the cable before final installation into a network.

Fiber optics are finding use in applications that operate in harshenvironments, such as aircraft, helicopters, unmanned vehicles,ship-board, space-craft and missiles. The fiber optic components must beable to operate and survive in an environment with severe shock,vibration, exposure to liquid contaminates, and over wide temperatureranges (such a −55 C to 125 C). These environmental stresses can causethe fiber end-faces, in physical contact within a connector, to becomedamaged or contaminated. Damage may occur when a particle trapped in theoptical interface is moved along the fiber end-face due to vibration,shock or thermal expansion/contraction. This movement may leavescratches on the polish surface of the fiber end-face. An environmentthat exposes the connector to liquid contaminate can compromise opticalcoupling if the liquid enters into an air gap between two fiber cores.

Therefore, there has been a long-standing need for systems and methodsfor providing more precise fiber end coupling. Details of such systemsand methods are provided below.

SUMMARY

The following presents a simplified summary in order to provide a basicunderstanding of some aspects of the claimed subject matter. Thissummary is not an extensive overview, and is not intended to identifykey/critical elements or to delineate the scope of the claimed subjectmatter. Its purpose is to present some concepts in a simplified form asa prelude to the more detailed description that is presented later.

According to a first aspect of the present disclosure, a system forapplication of one or more optical fiber protection devices to fiberferrule end-faces is presented, the system comprising: a cartridgecomprising stacked layers of a substantially same planar shape arrangedone above another, comprising in order from a top layer to a bottomlayer: a mechanical support comprising alignment openings thatcorrespond to a profile of a fiber ferrule end-face; an adhesive filmadhered to a bottom surface of the mechanical support, the adhesive filmcomprising perforate patterns that are aligned with the alignmentopenings and define outlines of the one or more optical fiber protectiondevices formed in the adhesive film; an applicator base plate used formounting of the cartridge during application of the optical fiberprotection device, and a cushion layer, formed by a compressiblematerial, that is arranged during application of the optical fiberprotection device, below the adhesive film of the stacked layers andabove the applicator base plate, wherein when applied to the fiberferrule end-face, an optical fiber protection device of the one or moreoptical fiber protection devices flexibly conforms around exposedoptical fiber ends in the fiber ferrule end-face.

According to a second aspect of the present disclosure, a method forprotecting a fiber ferrule end-face is presented, the method comprising:providing the above described system; mounting the cartridge of saidsystem on the applicator base plate, the applicator base plate having amain body of a substantially planar shape with dimensions equal to orgreater than dimensions of the cartridge; based on the mounting,orienting an adhesive side of the adhesive film away from the main body;inserting an end portion of the fiber ferrule end-face through analignment opening of the mechanical support; based on the inserting,adhering an optical fiber protection device of the one or more fiberprotection devices onto the fiber ferrule end-face; and pressing the endportion of the fiber ferrule end-face thereby releasing the opticalfiber protection device from the cartridge.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1A shows a perspective front view of a prior art multi-fiberconnector.

FIG. 1B shows a side view of the prior art multi-fiber connector of FIG.1A.

FIG. 2 shows an exemplary fiber protection device.

FIG. 3 shows an exemplary fiber protection device mounted on amulti-fiber connector.

FIG. 4 shows an exemplary fiber protection device with tabs.

FIG. 5 shows an exemplary fiber protection device with tabs mounted on amulti-fiber connector.

FIG. 6 shows an exemplary fiber optic coupling over a gap.

FIG. 7 shows a plot of an exemplary fiber optic coupling versus thewidth of the gap.

FIG. 8 shows an exemplary fiber protection device with an adhesivelayer.

FIG. 9 shows a side view of an exemplary fiber protection devices on amulti-fiber connector.

FIG. 10 shows two fiber connectors mated with an exemplary fiberprotection device in-between.

FIG. 11 shows two fiber connectors mated with two exemplary fiberprotection devices in-between.

FIG. 12A shows a top plan view of an exemplary cartridge for applyingthe fiber protection device.

FIG. 12B shows a cross-sectional view of the exemplary cartridge of FIG.12A comprising a plurality of stacked layers.

FIGS. 12C, 12D, 12E and 12F show top plan view details of each of theplurality of the stacked layers of the exemplary cartridge of FIG. 12B.

FIG. 12G shows an exemplary cushion layer used during application of thefiber protection device using the cartridge of FIG. 12A.

FIG. 13 shows an end portion of the fiber connector of FIG. 1A insertedthrough layers of the cartridge of FIG. 12A.

FIG. 14 shows an exemplary applicator base plate used to mount thecartridge shown in FIG. 12A for application of the fiber protectiondevice.

FIG. 15A shows an exemplary step of mounting the cartridge of FIG. 12Aonto the applicator base plate of FIG. 14, including mounting of thecushion layer of FIG. 12G onto the applicator base plate.

FIG. 15B shows an alternative step to the step shown in FIG. 15A ofmounting the cartridge of FIG. 12A onto the applicator base plate ofFIG. 14, wherein the cushion layer is part of the applicator base plate.

FIG. 15C shows the cartridge of FIG. 12A mounted onto the applicatorbase plate and ready for application of the fiber protection device ontoa fiber connector.

FIG. 15D shows a connector aligned with the mounted cartridge of FIG.15C in preparation for application of the fiber connector device ontothe connector end-face.

FIG. 15E shows the connector of FIG. 15D inserted into alignmentopenings of the cartridge and contacting an adhesive side of the fiberprotection device.

FIG. 15F shows the fiber protection device released from the cartridgeand adhered to the connector of FIG. 15E.

FIG. 15G shows the connector of FIG. 15E after application of the fiberprotection device.

FIG. 16A shows a single-use disposable pod according to an exemplaryembodiment of the present disclosure comprising stacked layers encasedwithin a casing.

FIG. 16B shows details of the stacked layers of the single-usedisposable pod of FIG. 16A.

FIG. 16C shows the single-use disposable pod of FIG. 16A with a covertape removed in preparation for application of a fiber protectiondevice.

FIG. 17A shows an alternative exemplary embodiment according to thepresent disclosure of a single-use disposable pod comprising a casingfitted with a snap and clip mechanism.

FIG. 17B shows further details of the stacked layers of the single-usedisposable pod of FIG. 17A.

FIG. 18 shows an exemplary single stamped metal part used to form thecasing of the single-use disposable pod of FIG. 16A.

FIG. 19 shows an exemplary process using a film-based fiber protectiondevice.

DETAILED DESCRIPTION

The exemplary fiber optic interface system, and the assembly method of atransparent layer within the interconnect system, are described in thisapplication. This system creates a fiber optic interface system thatplaces a thin transparent film, referred to herein as a fiber protectiondevice or a protection device, over the fiber end-faces at the connectorinterface. This system can use a (removable) film, designed to beremoved or replaced if necessary. The film is thin and transparentcreating minimal additional coupling loss between to fibers. Theadditional coupling loss can be small enough to allow fiber optic cabletesting and general use with the layer in place.

The system aids in optical coupling by preventing an air gap fromforming between the fiber cores within a connector. The system may alsoprevent damage to the fiber end-faces during cable manufacturing andgeneral use. The system may prevent foreign objects or liquids frombecoming trapped between the fiber cores within a connector.

The film that makes the protection device is applied in a manner thatcovers the end-faces of fibers at a connector interface. The filmsupplies compliance to allow the fiber end-faces to embed themselvesinto the film, making physical contact between the fiber core and thefilm. The film can be made up of multiple layers, such as an adhesivelayer and a structural layer. The adhesive layer can allow the film tobe applied and removed from the fiber end-faces. Ideally, the adhesivelayer leaves no residues on the fiber end-faces after removal.

The film can be part of a cartridge with a stacked layer constructionthat includes a mechanical support for holding the film. The mechanicalsupport can include alignment patterns/openings/holes to facilitateapplication of the fiber protection device to a connector end-face. Thefilm may be divided by perforate patterns that define one or more fiberprotection devices formed by the film. The cartridge can also provideprotection to an adhesive side of the film by way of a cover tape.

The cover tape may include perforate patterns for individual protectionof the adhesive side of each of the protection devices formed in thefilm. Such perforate patterns of the cover tape allow easy removal of aportion of the cover tape corresponding to a protection device to beapplied, thereby exposing the adhesive side of the protection device forapplication on a connector end-face. The film and the cover tape may beadhesively applied onto opposite faces of the mechanical support.

Each of the one or more protection devices may be applied to one or moreconnector end-faces using a same cartridge. Application of theprotection device using the cartridge can include aligning the fiberconnector end-face to the film via alignment patterns/holes formed intothe cartridge. According to an exemplary embodiment of the presentdisclosure, the cartridge, in combination with an applicator base plate,can provide a mechanical system for safe and efficient application ofthe protection device to a connector end-face. According to anotherembodiment of the present disclosure, the cartridge may be encased in acasing that in combination provide a similar mechanical system (e.g.,referred herein as a pod) for safe and efficient application of theprotection device. According to an exemplary embodiment, the podaccording to the present teachings can be a single-use disposable podthat is configured to include a single protection device and disposed ofafter application.

Further protection against scratches and damage to the film of theprotection device during application may be provided by sandwiching acushion layer between the cartridge and the applicator base plate. Thecushion layer may be made of a material that is soft enough not toscratch the film during application. Such material may be a flexibleand/or compressible material that provides, during application,compliance to the connector end-face. In turn, such compliance may allowa substantially uniform force exerted between the connector end-face andthe film so to promote uniform adhesion and outflow of any entrapped airbetween the connector end-face and the film. The material of the cushionlayer may be compressible enough to allow breaking of the perforatepatterns of the film that define the protection device and therebyreleasing the protection device from the cartridge and onto theconnector end-face. According to one embodiment of the presentdisclosure, the cushion layer may be pre-installed onto the applicatorbase plate and therefore considered part of the applicator base plate.According to another embodiment of the present disclosure, the cushionlayer may be provided with each cartridge and therefore be consideredpart of the cartridge. In this case, the cushion layer permanentlyprotects the film from scratches.

Applying the protection device to a fiber connector end-face may includemounting the cartridge onto the applicator base plate with the cushionlayer sandwiched between the cartridge and the applicator base plate,the cushion layer making contact with the film. This results in astacked layer configuration including, from bottom to top, theapplicator base plate, the cushion layer, the film, the mechanicalsupport, and the cover tape. Next, a portion of the cover tapecorresponding to the protection device to be applied is removed (peeledoff) by pulling and breaking corresponding perforate patterns of thecover tape. This in turn exposes the adhesive side of the film throughopenings (e.g., holes/patterns) provided in the mechanical support.Finally, the connector end-face is aligned with the openings and pressedthrough the openings, with a force exerted in the direction of theapplicator base plate, against the film. The force causes the protectiondevice to adhere onto the connector end-face. At the same time, theforce causes the compressible cushion layer to compress and thereforebreak the perforate patterns corresponding to the protection device tobe applied. Once the perforate patterns are broken, the protectiondevice, now adhered onto the connector end-face, is released. Finally,the protected connector is pulled back through the openings of themechanical support. Same steps can be performed to protect anotherconnector end-face using a different protection device of the samecartridge, or alternatively, a different cartridge.

The exemplary system(s) and method(s) according to the presentdisclosure has application in the general field of fiber optic cables.It can be used during the manufacturing process to protect the fiberend-face, without sacrificing the ability to measure the opticalcoupling properties of the cable. It can be used to protect fiber cablesthat are found in higher-level assemblies (such as modules, or box-levelsolutions) during the manufacturing and test process of the assembly.The exemplary system(s) and method(s) can aid the connector performancein harsh environment applications; and can relax the polishingspecifications normally required to create physical contact betweenfiber cores.

FIG. 1A is an illustration 110A of a prior art multi-fiber connector 110that is made up of a ferrule 115 that holds fibers 130 aligned to eachother and to an alignment mechanism 120. There are many types ofalignment mechanisms 120, including, but not exclusively, guide pin andguide holes, features that are processed monolithically into the ferrule115, or features that align the outer body of the ferrule 115, such as asleeve. The alignment mechanism 120 provides a means to align two of themulti-fiber connectors 110 together during the mating of end-faces 125of two sets of the fibers 130, so that light couples between the fibers.The fibers 130 can be polished or cleaved so that the ends of the fibersare roughly flat or at an angle. The fibers 130 and face 125 of theferrule 115 can be polished together in a single processing step. Thefibers 130 can protrude slightly from the ferrule 115 (e.g., end-face125 of the ferrule) to allow for physical contact with another set offibers (not shown) in a mating ferrule. A typical fiber protrusion is 1to 3 microns. The fibers 130 can be mounted into the ferrule 115 usingan adhesive that provides compliance to allow the fibers 130 to recesstoward the ferrule 115 when pressure is applied to the ends of thefibers 130 during connector mating. It should be apparent that theexposed fiber 103 ends, renders them susceptible to contamination (fromdebris, dust, etc.) or even damage. To date, there is no knownprotection scheme other than the installer perhaps placing a rag overthe multi-fiber connector 110 whilst preparing the mating connector. Thefollowing Figures show various improvements to the prior art.

FIG. 1B shows a side view of the connector 110 of FIG. 1A, where it isshown that a width w of an end portion (e.g., ferrule) 115 of theconnector 110 that includes the end-face 125 may be narrower than aremaining portion 135 of the connector 110. As can be seen in FIG. 1B, aheight h of the end portion 115 may also be smaller than a height of theremaining portion 135 of the connector 110. In the exemplary prior artconnector 110 of FIG. 1B, the alignment mechanism of the connector isshown as guide pins 120.

FIG. 2 shows one embodiment of an exemplary fiber protection device(protector) 150 comprising a transparent film 160. The film can haveclearance 170 regions to prevent mechanical interference with alignmentmechanisms 120, if present, or other features within the connector. Theclearance 170 features can aid in alignment of the film to the ferrule115 during the application process. The clearance 170 regions can have aclearance-to-edge slot 172 or other feature (micro slots aroundclearance 170, etc.) that eases the installation or removal of the fiberprotection device 150. The film 160 is thin and in some embodiments isapproximately less than 50 microns. The film should be soft enough toconform around the fiber end-face. In commercial embodiments, a Rockwellscale E hardness of the film in the range of approximately 30 and 150was found to be effective. Of course, other values may be foundeffective, depending on the implementation. A non-exhaustive list offilm materials that may be suitable are polyimide, polyethylene,polyurethane, and silicone. The fiber protection device 150 can bemanufactured by cutting or stamping a pattern into a film. A laser couldbe used for cutting the film, as well as other suitable manufacturingmethods. The fiber protection device 150 can be applied to a fiberconnector 202 having one or more fibers.

FIG. 3 shows an exemplary fiber protection device 150 mounted on a priorart multi-fiber connector 202, creating a protected connector 200. Thefiber protection device 150 covers the fiber(s) to create protectedfiber(s) 205. The fiber protection device 150 can have a clearancearound the alignment mechanism 204 on the fiber connector 202.

FIG. 4 shows an exemplary fiber protection device 250 with extendingtabs 260. In this exemplary embodiment according to the presentdisclosure, tabs 260 are provided onto the fiber protection device 250to ease in the removal of the film 160. The tabs 260 can be placed in anarea convenient to grasp that does not interfere with the overalloperation of the connector and be of any suitable shape or size.

FIG. 5 shows a multi-fiber connector 202 with a mounted fiber protectiondevice with tabs 250, creating a protected connector 300. In thisexemplary embodiment according to the present disclosure, the tabs 260are on two sides of the fiber protection device 250 and protrude aboveand below the fiber connector 202. It should be understood that whiletwo tabs 260 are shown, less or more tabs 260 may be used, according todesign preference.

The transparent fiber protection device 250 creates a small gap betweenfibers within a fiber connection. FIG. 6 shows is a closeup sideillustration showing the detail of fiber coupling over this gap from atransmit fiber to a receive fiber. The transmit fiber is made up of atransmit fiber core 336, which contains the light, and a transmit fibercladding 332. Similarly, the receive fiber has a receive fiber core 352and receive fiber cladding 356. The material for both the core and thecladding is glass having a different reflective index for the tworegions. The objective is to couple optical energy efficiently(typically >90%) from the transmit core to the receive core. The lightpath 328 within the transmit core 336 will experience a transmitreflection 344 at the end of the transmit fiber, and a receivereflection 348 at the start of the receive fiber. These are Fresnelreflections, caused by the difference in the index of refraction ofmaterials. Only when the gap 360 is reduced to zero thickness (d=0) arethe reflections nearly eliminated, since the fiber core materials have anearly identical index of reflections (i.e., the difference in indexwould result from fiber manufacturing non-uniformity). If the gap 360contained air, the magnitude of the Fresnel reflections would beapproximately 4%, resulting in 0.36 dB of optical signal loss from thecombined transmit reflection 344 and receive reflection 348. If the gap360 is filled with a transparent film 340 that nearly matches the fibercore index of refraction, the Fresnel reflections can be substantiallyreduced. Therefore, in commercial embodiments, a suitable index ofrefraction for the film was set to 1.5, the typical index of the fibercore. However, any film with an index of refraction between 1.1 and 2.2will produce less reflection than an air gap.

The film 340 can also create loss due to light scattering andabsorption. However, in a commercial embodiment, the amount ofscattering and absorption is negligible (<1%).

FIG. 7 is a plot showing measured results of fiber optic couplingbetween two fibers versus a film thickness. The type of fiber was a 50micron graded index multi-mode fiber. The film was a polyethylene. Thecoupling was measured for gap 360 thickness d at steps of 5 microns withthe gap filled with the film. A coherent laser source was used for thismeasurement, which shows up as some variations at gap thicknesses of d=5microns and d=10 microns. If an application had an acceptable lossbudget of −0.2 dB, a film thickness of roughly 25 microns would beexpected to be acceptable with this film.

According to an embodiment of the present disclosure, as illustrated inthe cross-sectional view 390 of FIG. 8, the transparent film 160 of thefiber protection device (e.g., 150 of FIG. 2, 250 of FIG. 4) can be atransparent adhesive tape that comprises a transparent adhesive layer394 overlying a transparent film 392. The transparent adhesive layer 394can aid securing the fiber protection device 150, 250, in place on theconnector. The adhesive layer 394 should be thin, for example, less than25 microns. In the process of making the fiber protection device 150,250, clearance 170 areas can be formed in the film (transparent adhesivetape) 160. Silicone or acrylate adhesives are possible candidates forthe transparent adhesive layer 394. Of course, other suitable adhesivesmay be used, according to design preference. The adhesive, in someembodiments, allows the fiber protection device 390 to be removedwithout leaving residue on the fiber connector 202. For outdoorenvironment applications, the transparent film (392) and the adhesivelayer (394) should be chosen to survive in temperature extremes and inthe presence of moisture.

The transparent film 392 can also be coated to improve the surfacequalities for optical (i.e., anti-reflection or absorption coatings) andmechanical reasons. For example, the mechanical qualities can beimproved with a diamond coating to provide resistance to scratches.

FIG. 9 shows a top side, cut-away view 400 of a single fiber protectiondevice 150 on a multi-fiber connector 100. The multi-fiber connector 110has alignment mechanisms 120, such as a guide hole or guide pin, andfiber ends 410 that protrude. Due to manufacturing variations, the fiberends 410 may not protrude uniformly across an array of fibers. The fiberends 410 are in contact with the fiber protection device 150 is a mannerthat reduces the Fresnel reflections at this interface. The top surfaceof the fiber protection device 150 can be substantially flat.

FIG. 10 shows a top side, cut-away view of a fiber connector 450 firstside 401 mated to a fiber connector second side 402 so that one or morefibers are brought into alignment for the purpose of optical coupling.In this embodiment, a single fiber protection device 150 is shown. Analignment hole first side 461 is aligned to alignment hole second side462 with an alignment pin 460. This shows one method of achievingalignment, however other methods are possible. A fiber protection device150 is applied to fiber connector first side 401. The fiber ends firstside 411 and fiber ends second side 412 are in physical contact with thefiber protection device 150. Light is coupled from the fiber ends firstside 411 to the fiber ends second side 412.

FIG. 11 shows a top side, cut-away view of a fiber connector 500 firstside 401 mated to a fiber connector second side 402 so that one or morefibers are brought into alignment for the purpose of optical coupling.In this embodiment, two fiber protection devices are utilized betweenthe respective connector fibers. An alignment hole first side 461 isaligned to alignment hole second side 462 with an alignment pin 460.This shows one method of achieving alignment, however other methods arepossible. A first side fiber protection device 505 is applied to fiberconnector first side 401. The fiber ends first side 411 are in physicalcontact with the first side fiber protection device 505. A second sidefiber protection device 510 is applied to fiber connector second side402. The fiber ends first side 412 are in physical contact with thesecond side fiber protection device 510. The first side fiber protectiondevice 505 is in physical contact with the second side fiber protectiondevice 510. Light is coupled from the fiber ends first side 411 to thefiber ends second side 412. Evident is the conforming of the fiberprotection devices 505 and 510 to the ends 411 and 412 of the respectivefibers, thus ensuring a non-air gap.

FIG. 12A shows a top plan view 1200A of an exemplary cartridge 820,according to an exemplary embodiment of the present disclosure, forapplying the fiber protection device (e.g., 150 of FIG. 2, 250 of FIG.4). As can be seen by the corresponding cross section view of FIG. 12B,the cartridge 820 may be formed by stacked layers, comprising amechanical support 805, the film 160 adhered, via an adhesive side 825of the film 160, onto one (bottom) face of the mechanical support 805,and a cover tape 1220 adhered onto the other (top) face of themechanical support 805. A cushion layer 1230 may optionally be providedas a layer that is positioned beneath the film 160. The cushion layer1230 may be formed by a material that naturally bonds, with a relativelyweak force, to the film 160.

With further reference to FIGS. 12A and 12B, the mechanical support 805can provide the mechanism of holding the film 160 and aligning of afiber connector to the film 160 for application of the fiber protectordevice. The mechanical support 805 can be patterned with alignmentopenings 810 that correspond to a profile of the connector end-face(i.e., end portion (ferrule) 115 of the connector 110 of FIG. 1A-1B).During application of the fiber protection device to the connectorend-face, the connector end-face is inserted through the alignmentopenings 810 which serve as alignment mechanism between the connectorand the fiber protection device. Accordingly, the alignment openings 810clear a contour (outer dimensions) of the connector end-face. Insertionof the connector end-face through the alignment openings 810automatically positions the connector end-face in alignment with theprotection device whose outlines are indicated in FIG. 12A by theperforate pattern 802. Also, insertion of the connector end-face throughthe alignment openings 810 automatically guides pins (if present, e.g.,120 of FIG. 1B) of the connector through the clearance 170 formed intothe protection device. As will be discussed with reference to FIGS. 14and 15, similar clearance 170 can be provided in the cushion layer (item170 of FIG. 12G later described) and in the applicator base plate (item1470 of FIG. 14, later described) for guiding of the pins. It should benoted that as shown in FIG. 12A, the fiber protection device mayoptionally include clearance-to-edge slots 172 or other micro slotsaround the clearance 170, as described above with reference to theexemplary embodiment of FIG. 2.

The cartridge 820 of FIG. 12A, in combination with an applicator baseplate (e.g., 1400 of FIG. 14 later described), may provide a mechanicalsystem for safe and efficient application of the protection device to aconnector end-face. For this, the cartridge 820 should be mounted ontothe applicator base plate with the film 160 side of the cartridge 820facing the applicator base plate. According to an embodiment of thepresent disclosure, the cartridge 820 is provided with a polarizing(alignment) pattern 1280 that guarantees correct orientation of thecartridge when mounted on the applicator base plate. Such polarizingpattern 1280 creates a mechanical interference with a structure of theapplicator base plate that is cleared only when the cartridge 820 iscorrectly mounted (film 160 facing the applicator base plate). Accordingto an exemplary embodiment, the polarizing pattern 1280 can comprise twoholes, as shown in FIG. 12A, which extend through all the layers (e.g.,1220, 805, 160 and 1230 of FIG. 12B) of the cartridge 820. As can beseen in FIG. 14, such holes of the polarizing pattern 1280 correspond tostructures (e.g., pins) 1480 of the applicator base plate 1400. A personskilled in art would clearly realize that other polarizing patterns canbe envisioned with more or less degrees of complexity and thereforecost. Combination of two pins (e.g., 1480) and two holes (e.g., 1280) tocreate a mechanical interference pattern is a simple, efficient andlow-cost solution to the polarization of the cartridge 820 for mountingonto the applicator base plate 1400. Other polarizing patterns caninclude one or more openings formed in the cartridge 820.

With continued reference to the cartridge 820 of FIG. 12A, perforatepatterns 1260 delimit regions 1250 of the cartridge 820 containing oneprotection device that is defined by corresponding alignment opening810. The perforate patterns 1260 are formed in the cover tape 1220,which is the top layer of the cartridge as shown in FIG. 12A.

According to an exemplary embodiment of the present disclosure and asshown in FIG. 12A, the perforate patterns 1260 may partition thecartridge in two rows and five columns, for a total of ten protectiondevices included in the cartridge 820. A person skilled in the art wouldclearly understand that such partitioning of the cartridge is purelyexemplary in nature and a function of dimensions of the cartridge 820and the connector end-face. Teachings according to the presentdisclosure can equally apply to connector end-faces of differentdimensions (e.g., corresponding 20 MT-RJ, 40 MT-RJ type connectors) aswell as to scaling up or down a dimension of the cartridge to includemore or less protection devices. Such scaling up/down of the dimensionsof the cartridge in view of dimensions of the connector end-faces can beregarded as parameters in the design of the cartridge according to thepresent teachings.

Furthermore, a person skilled in the art would clearly understand thatthe horizontal and vertical intersecting perforate patterns 1260 shownin FIG. 12A are purely exemplary in nature as other perforate patternsthat delimit regions 1250 can be envisioned. Although the regions 1250are shown as adjacent regions delimited by the (intersecting) perforatepatterns 1260, other (non-intersecting) perforate patterns that formnon-adjacent (not including a common perforate pattern) regions can beequally envisioned. In general, the perforate patterns 1260 may beformed by intersecting lines/curves or non-intersecting lines/curves.

FIG. 12C shows a top plan view of the cover tape 1220, including theperforate patterns 1260 and polarizing pattern 1280. As previouslydescribed, the cover tape 1220 can provide protection to an adhesiveside 825 of the film 160. The perforate patterns 1260 allow easy removalof a portion of the cover tape 1220, defined by region 1250 of FIG. 12A,corresponding to a protection device to be applied, thereby exposing theadhesive side 825 of the protection device for application on aconnector end-face, while maintaining protection of the adhesive side825 of other protection device of the cartridge 820. The cover tape 1220may be adhesively applied onto the mechanical support 805. According toan embodiment of the present disclosure, the cover tape 1220 may have athickness in a range of 50 microns to 500 microns and include a singleadhesive side. A person skilled in the art would know of many off theshelf tapes, made of different materials, colors, and according to saidthickness range, that may be used as the cover tape 1220 according tothe present teachings.

FIG. 12D shows a top plan view of the mechanical support 805, includingthe alignment openings 810 and the polarizing pattern 1280. Themechanical support 805 can provide structural rigidity to the cartridge820 and mechanical support for holding the film 160. The alignmentopenings 810 can provide alignment of the fiber connector end-face tothe film 160. The polarizing pattern 1280 provides a mechanicalinterference with a corresponding structure of the applicator base plate(1300 of FIG. 15) that clears only when the mechanical support 805 isoriented in a specific direction with respect to the applicator baseplate. According to an exemplary embodiment of the present disclosure,the mechanical support may be made via injection moulding using a basematerial of, for example, polycarbonate, or other similar material knownto a person skilled in the art. According to another exemplaryembodiment of the present disclosure, the mechanical support 805 may becut out from a sheet of material, via, for example, a laser cuttingprocess or any other process capable of providing sizes and relativepositioning of features (e.g., 810, 1280) of the mechanical support. Thematerial of such sheet may be any material capable of providing thestructural rigidity of the cartridge 820, and including material suchpolymers (e.g., plastic), metal, glass, ceramic or other organic ornon-organic material.

According to an exemplary embodiment of the present disclosure, themechanical support 805 may have a substantially uniform thickness in arange of 0.50 mm to 5.00 mm. Thickness of the mechanical support 805 ofFIG. 12D may be based on the height h of the end portion 115 of theconnector 110 (FIG. 1A, 1B) to be protected. Specifically, the thicknessof the mechanical support 805 is smaller than the height h by an amountε that is sufficiently large to allow the end portion 115 of theconnector 110 to protrude through the mechanical support 805 by anamount that is sufficient to break the perforate pattern 802 of the film160.

FIG. 12E shows a top plan view of the film 160, including the perforatepattern 802 that defines the fiber protection devices 150, the clearance170 that allows guiding of pins (e.g., 120 of FIG. 1A) of the connectorif present, and the polarizing pattern 1280. FIG. 12E shows the adhesiveside 825 of the film 160 facing up, which is what the connector end-facesees during application of the fiber protection device 150. Moredescription of the film 160, including thickness, material and layercomposition, is provided above with reference to FIGS. 2-5 and 8. As canbe seen in FIG. 12E, the perforate pattern 802 defines the fiberprotection device 150 described with reference to FIG. 2, and thereforedoes not include tabs 260 discussed with reference to the fiberprotection device 250 of FIG. 4.

FIG. 12F shows a top plan view of the film 160, including the perforatepattern 802 that defines the fiber protection devices 250, the clearance170 that allows guiding of pins (e.g., 120 of FIG. 1A) of the connectorif present, and the polarizing pattern 1280. FIG. 12F shows the adhesiveside 825 of the film 160 facing up, which is what the connector end-facesees during application of the fiber protection device 250. As can beseen in FIG. 12F, the perforate pattern 802 defines the fiber protectiondevice 250 described with reference to FIG. 4, and therefore includesthe tabs 260 discussed with reference to such figure. More descriptionof the film 160 is provided above with reference to FIGS. 2-5 and 8. Itshould be noted that during application of the fiber protection device250 via the cartridge 820, the end portion 115 of the connector 110 ofFIGS. 1A-1B is inserted through the alignment opening 810 so to pressagainst the film 160 thereby breaking the perforate pattern 802 whileadhering the bulk of the fiber protection device 250 to the end-face 120of the connector 110, at the exception of the tabs 260. When theprotected connector is pulled away from the cartridge 820, the (loose)tabs 260 fold back and follow through the alignment opening 810 providedin the mechanical support 805 of the cartridge 820. Once the protectedconnector is completely removed from the cartridge 820, the tabs 260 maybe folded and adhered onto the connector 110.

FIG. 12G shows a top plan view of the cushion layer 1230 which may beoptionally provided with the cartridge 820. As described above, althoughthe cushion layer 1230 may be required during application of the fiberprotection device according to the present teachings, it may be providedas part of the cartridge 820, or part of the applicator base plate(e.g., 1300 of FIG. 15), or as a standalone layer to be inserted betweenbetween the cartridge 820 and the applicator base plate prior toapplication of the fiber protection device. As can be seen in FIG. 12G,the cushion layer 1230 includes the clearance 170 for guiding of pins(e.g., 120 of FIG. 1A) of the connector if present, and the polarizingpattern 1280.

With continued reference to FIG. 12G, as described above, the cushionlayer 1230 protects the film 160 against scratches and damage duringapplication of the protection device (e.g., 150, 250). The cushion layer1230 may be made of a material that is soft enough not to scratch thefilm 160 during application. Such material may be a flexible and/orcompressible material that provides, during application, compliance tothe connector end-face (e.g., 120 of FIGS. 1A-1B). In turn, suchcompliance may allow a substantially uniform force exerted between theconnector end-face and the film 160 so to promote uniform adhesion andoutflow of any entrapped air between the connector end-face and the film160 during application. The material of the cushion layer may becompressible enough to allow breaking of the perforate pattern 802 ofthe film 160 that define the protection device and thereby releasing theprotection device from the cartridge 820 and onto the connectorend-face.

According to an exemplary embodiment of the present disclosure, thecushion layer 1230 of FIG. 12G may be a silicon layer made, for example,of soft silicon rubber, and have a substantially uniform thickness(e.g., h1 shown in FIG. 13) in a range of 0.50 mm to 5.00 mm.

According to an exemplary embodiment of the present disclosure, and withreference to FIG. 13, the thickness h1 of the cushion layer 1230 may bebased on the amount ε of the protrusion of the end portion 115 of theconnector 110 allowed by the thickness of the mechanical support 805.According to an exemplary embodiment of the present disclosure, thethickness h1 of the cushion layer 1230 in an uncompressed state may betwo times or more the amount ε. It should be noted that for claritypurposes, the layers of the cartridge 820 are shown in FIG. 13 asdistanced. Furthermore, FIG. 13 shows the end portion 115 of theconnector 110 inserted through the mechanical support 805 while a region1250 of the cover layer 1220 is removed to expose the adhesive side 825of the film 160 to the connector end-face 125.

FIG. 14 shows an exemplary applicator base plate 1400 used to mount thecartridge 820 shown in FIG. 12A for application of the fiber protectiondevice. According to an exemplary embodiment of the present disclosure,the applicator base plate 1400 has a profile that conforms to theprofile of the cartridge 820, including the cushion layer 1230.Accordingly, the applicator base plate 1400 has a main body 1410 with asubstantially flat surface that can be mated to an entirety of a surfaceof the cartridge 820 to provide complete mechanical support of thecartridge 820 during application. According to an exemplary embodimentof the present disclosure, the surface of the main body 1410 of theapplicator base plate 1400 and the surface of the cartridge 820,including the cushion layer 1230, are substantially of same dimensions.According to another exemplary embodiment of the present disclosure, thesurface of the main body 1410 of the applicator base plate 1400 hasdimensions that are larger than the dimensions of the surface of thecartridge 820.

With continued reference to FIG. 14, as previously described, theapplicator base plate 1400 may comprise one or more structures 1480 thatcreate a mechanical interference with the polarizing pattern 1280 of thecartridge, such mechanical interference cleared only when the cartridge820 is correctly oriented/aligned with the applicator base plate 1400.As can be seen in FIG. 14, the exemplary structures 1480 may be in theshape of cylindrical pins fitted to the main body 1410 that areconfigured to slide into the polarizing pattern 1280 when a correct faceof the cartridge 820 is presented to the applicator base plate 1400.Furthermore, a clearance(s) 1470 may be included in the main body of theapplicator base plate 1400 that correspond to an extension of theclearance 170 of the cartridge 820. As described above, such clearance1470 may be used during application of the fiber protection device toguide pins 120 of the connector 110 if present. Accordingly, provisionof the clearance 1470 may not be considered required if the connector110 is not expected to include the pins 120.

Material of the main body 1410 of the applicator base plate 1400 shownin FIG. 14 may be any hard (e.g., rigid and uncompressible) material,such as, for example, hard polymers, metal, glass, ceramic or other,such that, in combination with a thickness of the main body 1410, ashape of the main body 1410 is not deformed under pressure appliedduring application of the fiber protection device. A person skilled inthe art would know of many suitable materials which can be further basedon, for example, expected usage/storage environment, cost andmanufacturability.

Although not shown in FIG. 14, according to an exemplary embodiment ofthe present disclosure, the cushion layer 1230 may be permanently matedto the applicator base plate 1400. Accordingly, the cushion layer 1230may be glued onto the main body 1410 or simply press fitted through thepolarizing pattern 1280. Provision of the cushion layer 1230 as part ofthe applicator base plate 1400 may advantageously reduce cost of thecartridge 820 and ensure that the film 160 of the cartridge 820 isalways protected when mounted onto the applicator base plate 1400. Onthe other hand, provision of the cushion layer 1230 as part of thecartridge 820 ensures that the film 160 remains protected at all time,during storage and application, while increasing the cost of thecartridge 820.

FIG. 15A shows an exemplary step of mounting the cartridge 820 of FIG.12A onto the applicator base plate 1400 of FIG. 14, including mountingof the cushion layer 1230 of FIG. 12G between the applicator base plate1400 and the cartridge 820. As described above, the cushion layer 1230may be separate or part of the cartridge 820. Mounting of the cartridge820 and the cushion layer 1230 onto the applicator base plate 1400 mayinclude alignment and orienting of the polarizing pattern 1280 of thecartridge 820 with the structure 1480 of the applicator base plate 1400to clear a mechanical interference created between the polarizingpattern 1280 and the structure 1480. As described above, clearing of themechanical interference automatically positions the adhesive side 825 ofthe film 160 facing away from the applicator base plate 1400.

FIG. 15B shows an alternative step to the exemplary step shown in FIG.15A of mounting the cartridge 820 of FIG. 12A onto the applicator baseplate 1400 of FIG. 14 for a case where the cushion layer 1230 is part ofthe applicator base plate 1400. Similar to the step of FIG. 15A,mounting of the cartridge 820 onto the applicator base plate 1400, thatis fitted with the cushion layer 1230, includes alignment and orientingof the polarizing pattern 1280 of the cartridge 820 with the structure1480 of the applicator base plate 1400 to clear the mechanicalinterference created between the polarizing pattern 1280 and thestructure 1480. As described above, clearing of the mechanicalinterference automatically positions the adhesive side 825 of the film160 facing away from the applicator base plate 1400.

FIG. 15C shows a cross-sectional view along the line AA′ of FIG. 12A ofthe cartridge 820 of FIG. 12A mounted, via any one of the steps shown inFIGS. 15A and 15B, onto the applicator base plate 1400, and ready forapplication of the fiber protection device onto a fiber connector. Ascan be seen in FIG. 15C, the cover tape 1220 in a region 1250 of thecartridge 820 is removed by breaking a corresponding perforate pattern1260 of the cover sheet 1220, thereby exposing the adhesive side 825 ofthe film 160 through an alignment opening 810 formed in the mechanicalsupport 805.

As shown in FIG. 15D, in a next step to one of FIG. 15C, a connector 110is aligned with the alignment opening 810 in preparation to insertion ofthe connector 110 through the cartridge 820.

In a following step, as shown in FIG. 15E, the end portion 115 of theconnector 110 is inserted into the alignment opening 810 so that theend-face 125 of the connector 110 contacts the adhesive side 825 of thefilm 160 (in a region corresponding to a fiber protection device to beapplied). Optional pins 120 of the connector 110 are guided through theclearances 170 and 1470 provided by the cartridge 820 and the applicatorbase plate 1400.

Applying pressure (force) to the connector 110 shown in FIG. 15E, breaksthe perforate pattern 802 that defines the fiber protection device to beapplied onto the connector end-face 125, thus, as shown in FIG. 15F,releasing the protection device, adhered onto the connector end-face125, from the film 160. As described above and shown in FIG. 15E, thecushion layer 1230 compresses under pressure while providing complianceto the connector end-face 125. This in turn allows outflow of any airentrapped between the film 160 and the connector end-face 125 for anefficient adhesion of the fiber protection device onto said end-face,while protecting the film from any scratches.

Pulling the connector 110 shown in FIG. 15E out from the cartridge 820results in a protected connector 110 that as shown in FIG. 15F, isfitted with a fiber protection device 150, 250. As can be clearlyunderstood by a person skilled in the art, the mounted cartridge 820shown in FIG. 15G can be used for application of more fiber protectiondevices that are shown in the cartridge 820, protected via the covertape 1220. Removing a corresponding portion of the cover tape 1220 canbe followed with the steps shown in FIGS. 15A-15E for application ofanother fiber protection device of the cartridge 820. Subsequently, thecartridge 820 can be dismounted from the applicator base plate 1400 andstored away for a next application of remaining fiber protection devicesof the used cartridge 820.

As described above, the cartridge 820 in combination with the applicatorbase plate 1400 form a mechanical system for safe and efficientapplication of the protection device (e.g., 150, 250). In suchmechanical system according to the present disclosure, the applicatorbase plate 1400 can be considered as a constant component for mountingof cartridges 820. On the other hand, the cartridges 820 can beconsidered as consumables configured for application of the one or morefiber protection devices fitted in each of the cartridges 820.Accordingly, application of a fiber protection device of the cartridge820 may not be possible unless the applicator base plate 1400 isprovided. In some cases, it may be desirable to allow quick, safe, andefficient application of a fiber protection device according to thepresent teachings without requiring the relatively bulky and heavy baseplate 1400. It follows that according to an embodiment of the presentdisclosure a single use disposable pod that is configured to include asingle protection device is provided. This is shown in FIG. 16A.

FIG. 16A shows a single-use disposable pod 1600 according to anexemplary embodiment of the present disclosure, for application of asingle fiber protection device (e.g., 150, 250). The pod 1600 comprisesa casing 1615 that encases a plurality of stacked layers 1650 based onthe layers of the mechanical system provided by the combination of thecartridge 820 and the applicator base plate 1400 described above. Inother words, the stacked layers 1650 provide substantially samefunctionality (and therefore made of same material and absolute/relativethicknesses) as the layers 1220, 805,160, 1230 and 1410 (e.g. per FIG.15G) for a case where the one or more fiber protection devices isreduced to a single fiber protection device. Due to its small size andrelative light weight, the pod 1600 can be easily carried for onsiteapplication when needed. Once used, the pod 1600 can be disposed.

With continued reference to FIG. 16A, since the stacked layers 1650 arepre-arranged and encased within the casing 1615, no polarizing pattern(e.g., 1280) may be needed. According to an exemplary embodiment, thecasing 1615 may include clamps 1655 to steadily hold/clamp the stackedlayers 1650 within the casing 1615. According to a further exemplaryembodiment, a holding tab 1670 may be provided with the pod 1600 tofacilitate steady holding of the pod 1600 during application of thefiber protection device as well as ease removal of the cover tape 1620.

FIG. 16B shows details of the stacked layers 1650 of the single-usedisposable pod 1600. These include the cover tape 1620 that isequivalent in functionality to the cover tape 1220 of the cartridge 820,the mechanical support 1605 that is equivalent in functionality to themechanical support 805 of the cartridge 820, the film 1660 that isequivalent in functionality to the film 160 of the cartridge 820, thecushion layer 1630 that is equivalent in functionality to the cushionlayer 1230, and the base plate 1610 that is equivalent in functionalityto the main body 1410 of the applicator base plate 1400.

Based on the above description and figures related to the cartridge 820and the applicator base plate 1400, functionality of the stacked layers1650 of the single-use disposable pod 1600 should be clear. For example,as shown in FIG. 16B, the mechanical support 1605 of the single-usedisposable pod 1600 is provided with the alignment opening 810 that hasthe same functionality as the alignment opening 810 of the mechanicalsupport 805 of the cartridge 820. A person skilled in the art canclearly make parallels between the clearances 170 provided to the layers1660 and 1630 of the single-use disposable pod 1600 shown in FIG. 16B,and layers 160 and 1230 of the cartridge 820 shown in FIGS. 12A-12G.Similar parallels can be made between clearances 1470 provided to thelayer 1640 of the single-use disposable pod 1600 shown in FIG. 16B andto the main body 1410 of the applicator base plate shown in FIG. 14.Thicknesses (absolute or relative) and material used for the layers ofthe two configurations may also be same.

As described above, the single-use disposable pod 1600 of FIGS. 16A and16B may include a holding tab 1670 that protrudes (extends from) a maincommon surface area of the stacked layers 1650. An opening 1675 withinthe holding tab 1670 may be provided to facilitate removal of the covertape 1620 by allowing lifting a tab region 1625 of the cover tape 1620through the opening 1675 for peeling off the tab region 1670, andtherefore the entire cover tape 1620. As can be clearly taken from FIGS.16A and 16B, the tab region 1620 of the cover tape 1620 extends from amain body of the cover tape 1620 so to overlap a region of the holdingtab 1670 that includes the opening 1675. A person skilled in the artwould realize that such overlap may be a partial overlap of the holdingtab 1670 (e.g., per FIG. 16A) or a full overlap (not shown). As in thecase of the cartridge 820 described above, removal of the cover tape1620 may be performed in preparation for application of the fiberprotection device (e.g., 150, 250) by exposing the adhesive side 825 ofthe film 1660.

FIG. 16C shows the single-use disposable pod 1600 according to thepresent teachings with the cover tape 1620 removed. Accordingly, theadhesive side 825 of the of the fiber connection device 150 is exposedthrough the alignment opening 810 formed in the mechanical support 1605.Application of the fiber protection device 150 can therefore beperformed by following steps similar to the steps described above withreference to FIGS. 15C-15G. During application, the pod 1600 may bepositioned on a hard and flat surface, or alternatively held by handusing the case 1615 and/or the holding tab 1670.

A person skilled in the art would clearly understand that design of thecasing 1615 may be according to a variety of configurations which arebeyond the scope of the present disclosure. Accordingly, any casing thatcan steadily hold the stacked layers 1650 may be used in the single-usedisposable pod 1600 of the present teachings. In other words, steadilyholding via the clamps 1655 of FIG. 16A may be one possibleconfiguration of many. For example, FIG. 17A shows a single-usedisposable pod 1700 that comprises substantially same stacked layers1650 as the pod 1600 but encased in a casing 1715 that uses a snap andclip mechanism for steadily holding the stacked layers 1650, rather thanthe clamps 1655 of the pod 1600.

FIG. 17A shows an alternative exemplary embodiment according to thepresent disclosure of a single-use disposable pod 1700 comprising acasing 1715 fitted with a snap and clip mechanism to steadily hold thestacked layers 1650. As can be seen in FIG. 17A, the casing 1715comprises a main support plate 1765 upon which flexible clips 1755 areformed. The tips of the clips 1755 are shaped as lips 1758 that aredesigned to restrict a top opening into the casing 1715 by a slopedsurface of lips 1758. Accordingly, pushing the stacked layers 1650 fromthe top opening into the casing 1715 flexes the clips 1755 outwardlytill the lips 1758 are cleared from the region of the lips 1758. Oncethe lips 1758 are cleared, the clips 1755 relax (snap back) and steadilyhold the stacked layers 1650 within the casing 1715. It would be clearto a person skilled in the art that the stacked layers 1650 are heldfrom a vertical move by the top surface of the main support plate 1765and a bottom surface of the clips 1755. Accordingly, a distance betweensuch two surfaces should substantially match a height of the stackedlayers 1650 (not including, in some cases, the cover tape 1620). Furtherdetails of the stacked layers 1650 of the single-use disposable pod 1700are shown in FIG. 17B. Description of such stacked layers 1650 can befound in the above description as related to FIG. 16B.

Cost, manufacturability and environmental use of the single-usedisposable pod according to the present teachings may dictatedesign/material of the casing (e.g., 1615, 1715). The two exemplarycasing 1615 and 1715 described above can be made at low cost usingdifferent manufacturing methods and materials. For example, the casing1715 can be made as a single injection molded part using known methodsand materials (e.g., polymers). On the other hand, the casing 1615 canbe made via a single (flat) stamped metal part, such as the exemplarystamped metal part 1800 of FIG. 18, that is folded (e.g., inwards towardcenter (base 1810) of the metal part), along dotted lines 1805 shown inFIG. 18, to form a three dimensional structure of the casing 1615,including a base 1810, sidewalls 1820 and the clamps 1655. It would beclear to a person skilled in the art that the clamps 1655 may be foldedlast and after fitting the stacked layers 1650 within the sidewalls1820.

FIG. 19 is a process flow 1900 illustrating an example of filmprotection application. First, the ferrule has final processing thefiber end-face 1910. At this point the fiber ends are in their finalstate, such as polished or cleaved. These fibers are then inspected andtested for quality 1915 (for example, optical inspection with aninterferometer and optical coupling tests). If the quality is notacceptable 1920, the ferrule may be re-processed. If acceptable 1920,the film is applied 1925 via any of the cartridge 820 or the single-usedisposable pod 1600 of the present teachings. Then the ferrule isinspected and tested 1930. If the ferrule does not pass the test 1935,the film is re-applied 1925. If the ferrule passes the test 1935, it isoptionally assembled into a higher level cable 1940. The cable isshipped to a customer 1945. The customer can inspect and test the cable1950, insert the cable in a module 1955 and test the module inenvironmental conditions 1960. After testing the film can be optionallyremoved 1965 or left in place for final test 1970 and systemintegration.

In view of the above, it should be appreciated by one skilled in the artthat the functional blocks, methods, devices and systems described inthe present disclosure may be integrated or divided into differentcombinations of systems, devices, and functional blocks, as would beknown to those skilled in the art.

For example, while the process steps, algorithms or the like may bedescribed in a sequential order, such processes may be configured towork in different orders. In other words, any sequence or order of stepsthat may be explicitly described does not necessarily indicate arequirement that the steps be performed in that order. The steps ofprocesses described herein may be performed in any order practical.Further, some steps may be performed simultaneously despite beingdescribed or implied as occurring non-simultaneously (e.g., because onestep is described after the other step). Moreover, the illustration of aprocess by its depiction in a drawing does not imply that theillustrated process is exclusive of other variations and modificationsthereto, does not imply that the illustrated process or any of its stepsare necessary to the invention, and does not imply that the illustratedprocess is preferred.

While various aspects and embodiments have been disclosed herein, otheraspects and embodiments will be apparent to those skilled in the art.The various aspects and embodiments disclosed herein are for purposes ofillustration and are not intended to be limiting, with the true scopebeing indicated by the following claims.

1. A system for application of one or more optical fiber protectiondevices to fiber ferrule end-faces, comprising: a cartridge comprisingstacked layers of a substantially same planar shape arranged one aboveanother, comprising in order from a top layer to a bottom layer: amechanical support comprising alignment openings that correspond to aprofile of a fiber ferrule end-face; an adhesive film adhered to abottom surface of the mechanical support, the adhesive film comprisingperforate patterns that are aligned with the alignment openings anddefine outlines of the one or more optical fiber protection devicesformed in the adhesive film; an applicator base plate used for mountingof the cartridge during application of the optical fiber protectiondevice, and a cushion layer, formed by a compressible material, that isarranged during application of the optical fiber protection device,below the adhesive film of the stacked layers and above the applicatorbase plate, wherein when applied to the fiber ferrule end-face, anoptical fiber protection device of the one or more optical fiberprotection devices flexibly conforms around exposed optical fiber endsin the fiber ferrule end-face.
 2. The system according to claim 1,wherein the adhesive film has an index of refraction betweenapproximately 1.1-2.2, and a Rockwell scale E hardness of betweenapproximately 30-150.
 3. The system according to claim 2, wherein theadhesive film has a thickness in a range of 25 to 50 microns.
 4. Thesystem according to claim 3, wherein the adhesive film comprises: atransparent film formed from a material comprising polyimide,polyethylene, polyurethane, or silicone; and a transparent adhesivelayer having a thickness of less than 25 microns.
 5. The systemaccording to claim 4, wherein the transparent adhesive layer isconfigured to leave essentially no residues on the fiber ferruleend-face after removal of the optical fiber protection device.
 6. Thesystem according to claim 1, wherein the mechanical support has athickness in a range of 0.50 to 5.00 mm.
 7. The system according toclaim 6, wherein the thickness of the mechanical support is smaller thana height of an end portion of the fiber ferrule end-face by an amountthat is sufficient to break the perforate pattern of the adhesive filmduring application of the optical fiber protection device.
 8. The systemaccording to claim 1, wherein the mechanical support is a single piecesupport formed though injection molding.
 9. The system according toclaim 1, wherein the stacked layers of the cartridge further comprise:an adhesive cover tape adhered to a top surface of the mechanicalsupport, the adhesive cover tape configured to individually protect anadhesive side of each of the one or more optical fiber protectiondevices.
 10. The system according to claim 9, wherein individualprotection of the adhesive side of each of the one or more opticalprotection devices is provided via perforate patterns formed in theadhesive cover tape that provide a mechanical release for separation ofa region of the adhesive cover tape corresponding to each of thealignment openings.
 11. The system according to claim 1, wherein thecushion layer formed by the compressible material is configured, duringapplication of the optical fiber protection device, to sufficientlycompress so to allow release of the optical fiber protection device. 12.The system according to claim 11, wherein a thickness of the cushionlayer in an uncompressed state is in a range of 0.50 to 5.00 mm.
 13. Thesystem according to claim 11, wherein the thickness of the cushion layeris at least two times a difference between a height of an end portion ofthe fiber ferrule end-face and a thickness of the mechanical support.14. The system according to claim 1, wherein a combination of thecartridge and the cushion layer comprises a polarizing patternconfigured to provide a mechanical interference with the applicator baseplate for mounting of the cartridge during application of the opticalfiber protection device.
 15. The system according to claim 14, whereinthe polarizing pattern comprises one or more openings through thestacked layers and the cushion layer.
 16. The system according to claim15, wherein the applicator base plate comprises: a main body of asubstantially planar shape with dimensions equal to or greater thandimensions of the cartridge; a protruding structure configured to clearthe mechanical interference of the polarizing pattern for mounting ofthe cartridge only when an adhesive side of the adhesive film faces awayfrom the main body.
 17. The system according to claim 16, wherein theprotruding structure comprises pins.
 18. The system according to claim1, wherein the cushion layer is part of one of: a) the applicator baseplate, and b) the stacked layers.
 19. The system according to claim 1,wherein the optical fiber protection device is configured to preventcontamination of the exposed optical fiber ends and reduce Fresnelreflections.
 20. A method for protecting a fiber ferrule end-face,comprising: providing the system according to claim 1; mounting thecartridge of said system on the applicator base plate, the applicatorbase plate having a main body of a substantially planar shape withdimensions equal to or greater than dimensions of the cartridge; basedon the mounting, orienting an adhesive side of the adhesive film awayfrom the main body; inserting an end portion of the fiber ferruleend-face through an alignment opening of the mechanical support; basedon the inserting, adhering an optical fiber protection device of the oneor more fiber protection devices onto the fiber ferrule end-face; andpressing the end portion of the fiber ferrule end-face thereby releasingthe optical fiber protection device from the cartridge.
 21. The methodaccording to claim 20, wherein the mounting of the cartridge comprises:sandwiching the cushion layer between the main body and the cartridge.22. The method according to claim 20, further comprising: prior to theinserting: removing a portion of an adhesive protective tape adhered toa top surface of the mechanical support of the cartridge, therebyexposing the adhesive side of the adhesive film.